A method is provided for controlling the operating temperature of a catalytic reactor using a closed-loop system that provides for varying the reactor input and other operating parameters in order to maintain the operating temperature of the reactor at or near the initial setpoint temperature for operation of the reactor. In one example, maximum and minimum operating temperatures with a catalytic partial oxidation reactor are controlled, as well as maintaining control over the corresponding minimum required ratio of oxygen atoms to carbon atoms, such that the operating temperature within the reactor is maintained below the material limits but above threshold temperatures for coking.
Legal claims defining the scope of protection, as filed with the USPTO.
1. A method for controlling the operating temperature of a reactor in a catalytic partial oxidation process, the method comprising: a) feeding a mixture comprising a flow of air and a flow of a liquid distillate fuel through a spray nozzle into the reactor and reacting said mixture in a catalytic partial oxidation process to convert said mixture into a product mixture comprising hydrogen and carbon monoxide, wherein the reactor comprises a wire mesh substrate coated with rhodium supported on an alumina washcoat; b) maintaining a maximum observed operating temperature within the reactor at a temperature of less than 1100° C.; c) maintaining a minimum observed operating temperature within the reactor at a temperature greater than the threshold temperature for coking; d) varying the flow or air, or varying the flow of liquid distillate fuel, or alternately varying the flow of air and the flow of liquid distillate fuel so as to maintain in the mixture fed to the reactor a ratio of oxygen atoms in the air to carbon atoms in the fuel within a range of 1.0-1.2 while maintaining a temperature differential between the maximum observed operating temperature and the minimum observed operating temperature of less than 350° C.
2. The method of claim 1 where the maximum observed operating temperature is less than about 1050° C.
3. The method of claim 1 where the maximum observed operating temperature is between about 980° C. and about 1020° C.
4. The method of claim 3 where the minimum observed operating temperature is greater than about 700° C.
5. The method of claim 3 where the minimum observed operating temperature is greater than about 850° C.
6. The method of claim 1 wherein the temperature differential between the maximum observed operating temperature and the minimum observed operating temperature is less than 150° C.
7. An apparatus for controlling the operating temperature of a catalytic partial oxidation reactor comprising a) a catalytic partial oxidation reactor for converting a mixture comprising a flow of air and a flow of a liquid distillate fuel into a product mixture comprising hydrogen and carbon monoxide, the catalytic partial oxidation reactor comprising a wire mesh substrate coated with rhodium supported on an alumina washcoat; b) a means for maintaining a maximum observed operating temperature within the reactor of less than 1,100° C.; c) a means for maintaining a minimum observed operating temperature within the reactor at a temperature greater than the threshold temperature for coking; d) a spray nozzle for feeding the mixture comprising the flow of air and the flow of liquid distillate fuel into the reactor; e) a means for maintaining in the mixture fed to the reactor a ratio of oxygen atoms in the air to carbon atoms in the fuel within a range of 1.0-1.2 while maintaining a differential between the maximum observed operating temperature and the minimum observed operating temperature of less than 350° C.
8. The apparatus of claim 7 where the maximum observed operating temperature is less than about 1050° C.
9. The apparatus of claim 7 where the maximum observed operating temperature is between about 980° C. and about 1020° C.
10. The apparatus of claim 9 where the minimum observed operating temperature is greater than about 700° C.
11. The apparatus of claim 9 where the minimum observed operating temperature is greater than about 850° C.
12. The apparatus of claim 7 wherein the temperature differential between the maximum observed operating temperature and the minimum observed operating temperature is less than 150° C.
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February 9, 2009
December 25, 2012
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